Mattress foundation kit

ABSTRACT

Disclosed is a mattress foundation kit configured to be assembled by a user. The mattress foundation kit may include a plurality of rails, wherein each rail is a longitudinal member constructed of a structural foam core connected, for example by being permanently laminated, with at least one supporting material. Further, the mattress foundation kit may include a plurality of interconnecting members corresponding to the plurality of rails. Moreover, the mattress foundation kit may include a plurality of retainer clips attached along a side of at least two rails of the plurality of rails. Yet further, the mattress foundation kit may include a plurality of slats corresponding to the plurality of retainer clips, wherein the plurality of slats is configured to support a mattress, wherein each end of a slat is configured to detachably engage with a corresponding retainer clip.

FIELD OF INVENTION

The present disclosure generally relates to a mattress foundation. Morespecifically, the present disclosure relates to a knock down mattressfoundation kit.

BACKGROUND OF THE INVENTION

Conventional bedding structures commonly have separate beddingcomponents which together form a system having an upper mattress restingon top of a mattress foundation, which in turn rests over a floorsurface. In some cases, the mattress foundation may be supported by legsextending from the mattress foundation towards the floor surface.Mattress foundations provide support and firmness to the mattress.Foundations are typically constructed of a frame, such as a rectangularframe including perimeter members and internal members.

With the rise of e-commerce, end users may order mattress foundationsonline. However, traditional mattress foundations are generally sold assingle units. Therefore, they require freight or truck carriers to bedelivered to an end user. This causes increased cost and delays indelivering the mattress foundation to end users.

Further, it is challenging to carry the mattress foundations in highrise buildings. The mattress foundations must traverse stairs or freightelevators in the high-rise buildings to arrive to the end user.

Accordingly, there is a need for improved mattress foundations that maybe transported easily to end users.

SUMMARY OF THE INVENTION

Disclosed is a mattress foundation kit configured to be assembled by auser. The mattress foundation kit may include a plurality of rails.Further, each rail may be a longitudinal member. In an embodiment, eachrail may be constructed of, for example, a structural foam coreconnected, for example by being permanently laminated, with at least onesupporting material. Furthermore, the mattress foundation kit mayinclude a plurality of interconnecting members corresponding to theplurality of rails. Moreover, the mattress foundation kit may include aplurality of retainer clips attached along a side of at least two railsof the plurality of rails. Yet further, the mattress foundation kit mayinclude a plurality of slats corresponding to the plurality of retainerclips. In some embodiments, the plurality of slats may be configured tosupport a mattress such that each end of a slat may be configured todetachably engage with a corresponding retainer clip.

According to some aspects, a method of manufacturing a mattressfoundation kit is disclosed. The method may include permanentlylaminating at least one supporting material onto each rail of aplurality of rails. Further, each rail may be a longitudinal member. Inan embodiment, each rail may be constructed of, for example, astructural foam core. Furthermore, the method may include permanentlylaminating a plurality of interconnecting members onto the plurality ofrails. Additionally, each interconnecting member may be connected, forexample by being permanently laminated, to at least one part of acorresponding rail of the plurality of rails. Moreover, a firstinterconnecting member of a first rail of the plurality of rails may beconfigured to detachably engage with a second interconnecting member ofa second rail of the plurality of rails. Finally, the method may includeattaching a plurality of retainer clips along a side of at least tworails of the plurality of rails. Further, each retainer clip may beconfigured to detachably engage with a slat of a plurality of slatsconfigured to support a mattress.

According to some aspects, a mattress foundation kit is disclosed. Thekit may be configured to be assembled by a user. The mattress foundationkit may include a plurality of rails, a plurality of interconnectingmembers corresponding to the plurality of rails, a plurality of retainerclips attached along a side of at least two rails of the plurality ofrails, a plurality of slats and a plurality of securing members.

According to some further aspects, the plurality of interconnectingmembers includes a plurality of male interconnecting members and aplurality of female interconnecting members. A male interconnectingmember may be configured to detachably engage with a femaleinterconnecting member. Further, the plurality of rails may beinterconnected using the interconnecting members to form arectangular-shaped or a square shaped frame.

According to some further aspects, the rectangular-shaped or the squareshaped frame may also include one or more mid rails to provide supportto the frame.

According to some aspects, the mattress foundation kit may include aplurality of rails, a plurality of interconnecting members correspondingto the plurality of rails, a plurality of retainer clips attached alonga side of at least two rails of the plurality of rails, a plurality ofslats, a plurality of securing members and a plurality of legscorresponding to the plurality of rails. The plurality of legs may beconfigured to support the mattress foundation on the ground such that atleast one end portion of each leg is configured to be detachablyattached to an interconnecting member on a corresponding rail of theplurality of rails.

According to some further aspects, at least one rail of the plurality ofrails of the mattress foundation kit may include a drawer openingconfigured to receive a drawer configured to function as a storagecompartment.

According to some further aspects. a knock down mattress foundation kitis disclosed. The mattress foundation kit may be light weight, compactand can be easily assembled by an end user. The mattress foundation kitmay be designed for internet sales to accompany internet sales ofmattresses. Accordingly, the mattress foundation kit may be stored in abox of a certain volume, such that the mattress foundation kit may beshipped through courier services, such as, but not limited to, FedEx andUPS, without necessarily requiring transport through large vehicles suchas trucks. For example, the mattress foundation kit may be capable ofbeing stored within a volume represented by dimensions of 9″, 10″, and80″.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an illustration of a mattress foundation kit in accordancewith some embodiments.

FIG. 1B is an illustration of a plurality of slats comprised in themattress foundation kit of FIG. 1A.

FIG. 2 is a close-up view of a portion of the mattress foundation kit ofFIG. 1A illustrating mating of a male interconnecting member and afemale interconnecting member attached to the plurality of rails.

FIG. 3 is a close-up view of a portion of the mattress foundation kit ofFIG. 1A illustrating engagement of a mid rail with an end rail.

FIG. 4 is a close-up view of a portion of the mattress foundation kit ofFIG. 1A illustrating a plurality of retainer clips attached to a side ofa rail.

FIG. 5 is a perspective view of a mattress foundation built using themattress foundation kit of FIG. 1A.

FIG. 6 is a top view of the mattress foundation of FIG. 5.

FIG. 7 illustrates multiple views of a corner male interconnectingmember for a rail of the mattress foundation kit of FIG. 1A.

FIG. 8 illustrates multiple views of a corner female interconnectingmember for a rail of the mattress foundation kit of FIG. 1A.

FIG. 9 illustrates multiple views of a mid rail male interconnectingmember of the mattress foundation kit of FIG. 1A.

FIG. 10 illustrates multiple views of a mid rail female interconnectingmember of the mattress foundation kit of FIG. 1A.

FIG. 11 illustrates multiple views of a securing member forinterconnecting the rails of the mattress foundation kit of FIG. 1A.

FIG. 12 is a flowchart depicting a method for manufacturing the mattressfoundation kit of FIG. 1A in accordance with some embodiments.

DETAIL DESCRIPTIONS OF THE INVENTION

All illustrations of the drawings are for the purpose of describingselected versions of the present invention and are not intended to limitthe scope of the present invention.

This overview is provided to introduce a selection of concepts in asimplified form that are further described below. The overview is notintended to identify key features or essential features of the claimedsubject matter. Further, the overview is not intended to be used tolimit the claimed subject matter's scope.

The present disclosure relates generally to a knock down mattressfoundation kit that may, in some embodiments, be light weight, compactand easily assembled by an end user. The mattress foundation kit may bedesigned for internet sales to accompany internet sales of mattresses.Accordingly, the mattress foundation kit may be stored in a box of acertain volume, such that the mattress foundation kit may be shippedusing courier services, without necessarily requiring transport throughlarge vehicles such as trucks.

Disclosed is a mattress foundation kit 100 configured to be assembled bya user. FIG. 1A illustrating a mattress foundation kit 100 in accordancewith some embodiments. The mattress foundation kit 100 includes multiplerails 102, 104, 106, 108, and 110. The multiple rails 102, 104, 106,108, and 110 may be configured to form, for example, a rectangular frameof a mattress foundation. The multiple rails 102, 104, 106, 108, and 110may include a pair of side rails 102 and 106, a pair of end rails 104and 108 and a mid rail 110. Each rail may be a longitudinal memberconstructed of, for example, but not limited to, a structural foam coreconnected, for example by being permanently laminated, with a supportingmaterial. In general, the plurality of rails may be constructed of astrong and light weight material. The supporting material may be, but isnot limited to, wood, plastic, metal, and composite material. Further,each of a top side and a bottom side of the structural foam core may beconnected, for example by being permanently laminated, with thesupporting material.

The pair of side rails 102 and 106 may form the longer sides of therectangular frame of the mattress foundation. Likewise, the pair of endrails 104 and 108 may form the shorter sides of the rectangular frame. Afirst end portion 112 of the mid rail 110 may be configured to bedetachably engaged with one rail (say, the end rail 104) of the pair ofend rails 102 and 106. A second end portion 114 of the mid rail 110 maybe configured to be detachably engaged with the other rail (say, the endrail 108) of the pair of end rails 102 and 106.

The multiple rails 102, 104, 106, 108, and 110 may further includemultiple interconnecting members 116, 118, 120, 122, 124, 126, 128, 130,132, 134, 136 and 138. Each interconnecting member may be connected, forexample by being permanently laminated, to at least one part of acorresponding rail of the multiple rails 102, 104, 106, 108 and 110.Alternatively, in some embodiments, each interconnecting member may bedetachably connectable to a corresponding rail. Additionally, in someembodiments, each of a rail and corresponding one or moreinterconnecting members may be integrally formed. For example, a railwith a pair of interconnecting members disposed on either ends of therail may be formed using a single mold, using for instance, an injectionmolding process. Alternatively, each of the rail and the pair ofinterconnecting members may be separately formed and connected togetherthereafter.

Further, a first interconnecting member of a first rail of the multiplerails 102, 104, 106, 108 and 110 may be configured to detachably engagewith a second interconnecting member of a second rail of the multiplerails 102, 104, 106, 108 and 110. This is explained in further detail inconjunction with FIGS. 2-4 below which show close-up views of regions140, 142 and 144.

The multiple interconnecting members 116, 118, 120, 122, 124, 126, 128,130, 132, 134, 136 and 138 further include multiple corner maleinterconnecting members 116, 120, 124 and 128, and multiple mid railmale interconnecting members 132 and 136. The multiple interconnectingmembers 116, 118, 120, 122, 124, 126, 128, 130, 132, 134, 136 and 138further include multiple corner female interconnecting members 118, 122,126, and 130, and multiple mid rail female interconnecting members 134and 138. The multiple male interconnecting members 116, 120, 124, 128,132 and 136 and the multiple corner female interconnecting members 118,122, 126, 130 may be connected, for example by being permanentlylaminated, to an end portion of a corresponding rail. Further, themultiple mid rail female interconnecting members 134 and 138 may beconnected, for example by being permanently laminated, to a side portionof the end rails 104 and 108 respectively. A male interconnecting memberis configured to detachably engage with a female interconnecting member.Additionally, in some embodiments, the male interconnecting member maybe engaged with the female interconnecting member through a lockingmechanism in order to secure the engagement against, for example, weightof a mattress and/or a user on the mattress foundation.

The multiple corner male interconnecting members 116, 120, 124 and 128are explained in detail in conjunction with FIGS. 7A-H. The multiplecorner female interconnecting members 118, 122, 126, and 130 areexplained in detail in conjunction with FIGS. 8A-H. The multiple midrail male interconnecting members 132 and 136 are explained in detail inconjunction with FIGS. 9A-H. The multiple mid rail femaleinterconnecting members 134 and 138 are explained in detail inconjunction with FIGS. 10A-H.

The mattress foundation kit 100 may further include multiple slats 146shown in FIG. 1B. The multiple slats 146 may be configured to support amattress. This is explained in further detail in conjunction with FIG. 4below.

Yet further, the mattress foundation kit 100 may include multiplesecuring members 148, 150, 152 and 154 corresponding to the multiplemale interconnecting members 116, 120, 124, 128, 132 and 136, and themultiple female interconnecting members 118, 122, 126, 130, 134 and 138.

Referring to FIG. 2, a close-up view of a portion 140 of the mattressfoundation kit 100 is shown. The corner male interconnecting member 120is shown attached to the end rail 104. The corner female interconnectingmember 118 is shown attached to the side rail 102. The corner maleinterconnecting member 120 may detachably engage with the corner femaleinterconnecting member 118. Thereafter, the securing member 148 may beused to detachably engage with each of the corner male interconnectingmember 120 and the corner female interconnecting member 118.Accordingly, the securing member 148 secures the engaged interconnectingmembers. The securing member 148 may be, but not limited to, a machinescrew, a sheet metal screw, a wood screw, an eye bolt, a socket screw,an elevator bolt and a pin. For instance, some mechanisms used for thesecuring member 148 may be attached and detached without use of tools,while others may require use of a tool. Further, in some embodiments,the securing member 148 may be formed as a wedge.

Referring to FIG. 3, a close-up view of a portion 142 of the mattressfoundation kit 100 is shown. The mid rail male interconnecting member132 is shown attached at the end 112 of the mid rail 110. The mid railfemale interconnecting member 134 is shown attached to a side of the endrail 104. The mid rail male interconnecting member 132 may be detachablyengaged with the mid rail female interconnecting member 134 by insertingthe mid rail male interconnecting member 132 within the mid rail femaleinterconnecting member 134.

Referring to FIG. 4, a close-up view of a portion 144 of the mattressfoundation kit 100 is shown. Each of the side rails 102 and 106 includemultiple retainer clips 156 attached along the length of each side rail102, 106. The mattress foundation kit 100 includes the multiple slats146 corresponding to the multiple retainer clips 156. Each end of a slatis configured to detachably engage with a corresponding retainer clip.The multiple slats are configured to support a mattress. The multipleslats 156 may be constructed using one or more of wood, plastic, metal,and composite material. Further, in some embodiments, each slat of themultiple slats 156 may be shaped as a rod.

As mentioned before, the mattress foundation kit 100 of FIG. 1A may beconfigured to be assembled by a user. The user may first engage themultiple rails 102, 104, 106, 108, and 110 to form, for example, arectangular frame. For example, the user may engage the side rail 102with the end rail 104, the end rail 104 with the side rail 106, the siderail 106 with the end rail 108 and the end rail 108 with the side rail102 to form the rectangular frame of the mattress foundation 500.However, in other embodiments, the mattress foundation kit 100 mayenable the user to form a frame in the shape of a regular and/or anirregular polygon. Then, the user may engage the multiple slats 146 withthe multiple retainer clips 156 to obtain the mattress foundation 500shown in FIG. 5. A top view of the mattress foundation 500 is shown inFIG. 6.

FIGS. 7A-H illustrate multiple views of the corner male interconnectingmember 120 of the mattress foundation 100. Specifically, FIG. 7Aillustrates a front view, 7B a back view, 7C a right side view, 7D aleft side view, 7E a top view, 7F a bottom view, 7G a first perspectiveview and 7H a second perspective view.

The corner male interconnecting member 120 may include a clip 702 with aU-shaped cross-section (shown in FIGS. 7E and 7F). For example, the clip702 may be made of sheet metal folded over in a U-shaped profile toprovide parallel clip faces and one of the clip faces has at least oneslit bordering a strip of the sheet metal which is bowed out. The height704 of the clip 702 may be approximately same as the height of the endrail 104. Further, the width 706 of the clip 702 may be slightly morethan the width of the end rail 104, such that the clip 702 can besecured to the end rail 104. The back side of the clip 702 includes acylindrical sleeve 708. The height of the sleeve 708 may be roughly halfthe height of the clip 702. The cylindrical sleeve 708 may be located atthe center of back of the clip 702. The cylindrical sleeve 708 may behollow and include a cylindrical hole 710 along the length of thecylindrical sleeve 708 and inside the cylindrical sleeve 708.

FIGS. 8A-H illustrates multiple views of the corner femaleinterconnecting member 118 of the mattress foundation kit 100.Specifically, FIG. 8A illustrates a front view, 8B a back view, 8C aright side view, 8D a left side view, 8E a top view, 8F a bottom view,8G a first perspective view and 8H a second perspective view.

The corner female interconnecting member 118 may include a clip 802 witha U-shaped cross-section, similar to the clip 702. The height 804 of theclip 802 may be approximately same as the height of the side rail 102.Further, the width 806 of the clip 802 may be slightly more than thewidth of the side rail 102, such that the clip 802 can be secured to theside rail 102. The back side of the clip 802 includes two cylindricalsleeves 808 and 810. The cylindrical sleeve 808 is hollow and includes acylindrical hole 812 along the length of the cylindrical sleeve 808 andinside the cylindrical sleeve 808. Similarly, the cylindrical sleeve 810is hollow and includes a cylindrical hole 814 along the length of thecylindrical sleeve 810 and inside the cylindrical sleeve 810. Thecombined total height of the two sleeves 808 and 810 may be roughly halfthe height of the clip 802. The cylindrical sleeves 808 and 810 may beseparated, which creates a receptacle 816 between them. The height ofthe receptacle 816 may be slightly more than the height of the sleeve708, such that the receptacle 816 may receive the cylindrical sleeve708. When the cylindrical sleeve 708 is placed in the receptacle 816,the three cylindrical holes 710, 812 and 814 align, such that a securingmember 148 (such as the pin 148) may pass through the three cylindricalholes 710, 812 and 814. Accordingly, the pin may secure the side rail102 and the end rail 104. Similarly, the end rail 104 and the side rail106 may be secured. Further, the side rail 106 and the end rail 108 maybe secured. Finally, the end rail 108 and the side rail 102 may besecured to form, for example, a rectangular frame of the mattressfoundation 500.

FIGS. 9A-H illustrates multiple views of the mid rail maleinterconnecting member 132 of the mattress foundation kit 100.Specifically, FIG. 9A illustrates a right side view, 9B a left sideview, 9C a front view, 9D a back view, 9E a top view, 9F a bottom view,9G a first perspective view and 9H a second perspective view.

The mid rail male interconnecting member 132 includes a clip 902 with aU-shaped cross-section, similar to the clip 702. The height 904 of theclip 902 may be approximately same as the height of the mid rail 110.Further, the width 906 of the clip 902 may be slightly more than thewidth of the mid rail 110, such that the clip 902 may be secured to themid rail 110. The back side of the clip 902 may include a rectangularprojection 908.

FIGS. 10A-H illustrates multiple views of the mid rail femaleinterconnecting member 134 of the mattress foundation kit 100.Specifically, FIG. 10A illustrates a front view, 10B a back view, 10C aleft side view, 10D a right side view, 10E a top view, 1° F. a bottomview, 10G a first perspective view and 10H a second perspective view.

The mid rail female interconnecting member 134 may generally have arectangular shape with a rectangular depression 1002 in the middle ofthe mid rail female interconnecting member 134. The rectangulardepression 1002 is closed from five sides. However, it is an opening1004. Further, the size of the rectangular depression 1002 may beslightly bigger than the rectangular projection 908 such that at least aportion of the rectangular projection 908 fits inside the rectangulardepression 1002.

The rectangular depression 1002 may also have two holes 1006, 1008 ontwo opposite sides of the rectangular depression 1002. Further, therectangular projection 908 may have a hole (not shown) across itsbreadth. When the rectangular projection 908 is placed inside therectangular depression 1002, the hole on the rectangular projection 908and the two holes 1006, and 1008 may align such that a pin may securethe mid rail male interconnecting member 132 and the mid rail femaleinterconnecting member 134 together.

FIGS. 11A-E illustrates multiple views of the securing member 148 forinterconnecting the rails of the mattress foundation kit 100.Specifically, FIG. 11A illustrates a side view, 11B a top view, 11C abottom view, 11D a first perspective view and 11E a second perspectiveview.

The securing member 148 may have sufficient length to be able to passthrough the holes in the respective interconnecting members (forexample, the holes 710, 812, 814) and secure the same. In someembodiments, the securing member 148 may have a threaded portion thatmay engage with a nut. Alternatively, the holes in the respectiveinterconnecting members (for example, the holes 710, 812, 814) may bethreaded from inside to engage with the threads on the securing member148. Further, securing member 148 may be hollow along the length of thesecuring member 148, such that in includes a hole 1102.

FIG. 12 is a flowchart depicting a method 1200 for manufacturing themattress foundation kit of FIG. 1A in accordance with some embodiments.At step 1202, the method 1200 includes permanently laminating at leastone supporting material onto each rail of the multiple rails (forexample the multiple rails 102, 104, 106, 108 and 110). Each rail is alongitudinal member constructed of, for example, but not limited to, astructural foam core.

Next, at step 1204, the method 1200 includes permanently laminatingmultiple interconnecting members (for example, the multipleinterconnecting members 116, 118, 120, 122, 124, 126, 128, 130, 132,134, 136 and 138) onto the multiple rails. Each interconnecting memberis connected, for example by being permanently laminated, to at leastone part of a corresponding rail of the multiple rails. Further, a firstinterconnecting member of a first rail of the plurality of rails isconfigured to detachably engage with a second interconnecting member ofa second rail of the multiple rails.

Finally, at step 1206, the method 1200 includes attaching multipleretainer clips along a side of at least two rails of the multiple rails.Each retainer clip is configured to detachably engage with a slat ofmultiple slats configured to support a mattress.

Although the invention has been explained in relation to its preferredembodiment, it is to be understood that many other possiblemodifications and variations can be made without departing from thespirit and scope of the invention. Obvious changes, modifications, andsubstitutions may be made by those skilled in the art to achieve thesame purpose the invention. The exemplary embodiments are merelyexamples and are not intended to limit the scope of the invention. It isintended that the present invention cover all other embodiments that arewithin the scope of the descriptions and their equivalents.

The following is claimed:
 1. A mattress foundation kit configured to beassembled by a user, the mattress foundation kit comprising: a pluralityof rails, wherein each rail is a longitudinal member; a plurality ofinterconnecting members corresponding to the plurality of rails, whereineach interconnecting member is connected to at least one part of acorresponding rail of the plurality of rails, wherein a firstinterconnecting member of a first rail of the plurality of rails isconfigured to detachably engage with a second interconnecting member ofa second rail of the plurality of rails; a plurality of retainer clipsattached along a side of at least two rails of the plurality of rails;and a plurality of slats corresponding to the plurality of retainerclips, wherein each end of a slat is configured to detachably engagewith a corresponding retainer clip.
 2. The mattress foundation kit ofclaim 1, wherein each rail is a longitudinal member constructed of astructural foam core connected with at least one supporting material. 3.The mattress foundation kit of claim 2, wherein the at least onesupporting material comprises at least one of wood, plastic, metal, andcomposite material.
 4. The mattress foundation kit of claim 2, whereineach of a top side and a bottom side of the structural foam core isconnected with the at least one supporting material.
 5. The mattressfoundation kit of claim 1, wherein the plurality of interconnectingmembers comprises a plurality of male interconnecting members and aplurality of female interconnecting members, wherein a maleinterconnecting member is configured to detachably engage with a femaleinterconnecting member.
 6. The mattress foundation kit of claim 5further comprising a plurality of securing members corresponding to theplurality of male interconnecting members and the plurality of femaleinterconnecting members, wherein a securing member is configured todetachably engage with each of a corresponding male interconnectingmember and a corresponding female interconnecting member.
 7. Themattress foundation kit of claim 6, wherein a securing member comprisesa pin.
 8. The mattress foundation kit of claim 7, wherein the pin isformed as a wedge.
 9. The mattress foundation kit of claim 1, whereineach interconnecting member is connected to an end portion of acorresponding rail.
 10. The mattress foundation kit of claim 1, whereinat least one interconnecting member is connected to a side portion of acorresponding rail.
 11. The mattress foundation kit of claim 10, whereinat least two interconnecting members are connected to the side portionof the corresponding rail.
 12. The mattress foundation kit of claim 1,wherein the plurality of slats is constructed of at least one of wood,plastic, metal, and composite material.
 13. The mattress foundation kitof claim 1, wherein each slat of the plurality of slats is shaped as arod.
 14. The mattress foundation kit of claim 1, wherein the pluralityof rails comprises each of a pair of side rails, a pair of end rails anda mid-rail, wherein the plurality of rails is configured to form arectangular frame, wherein the pair of side rails forms the longer sidesof the rectangular frame, wherein the pair of end rails forms theshorter sides of the rectangular frame, wherein a first end portion ofthe mid rail is configured to be detachably engaged with one rail of thepair of end rails, wherein a second end portion of the mid rail isconfigured to be detachably engaged with the other rail of the pair ofend rails.
 15. The mattress foundation kit of claim 1, wherein at leastone of a side rail, an end rail and a mid rail comprises of a pluralityof rails.
 16. The mattress foundation kit of claim 1 further comprisinga plurality of legs corresponding to the plurality of rails, wherein theplurality of legs is configured to support the mattress foundation onthe ground, wherein at least one end portion of each leg is configuredto be detachably attached to an interconnecting member on acorresponding rail of the plurality of rails.
 17. The mattressfoundation kit of claim 1, wherein at least one rail of the plurality ofrails comprises a drawer opening configured to receive a drawerconfigured to function as a storage compartment.
 18. The mattressfoundation kit of claim 1, wherein at least one rail of the plurality ofrails is integrally formed with at least one correspondinginterconnecting member of the plurality of interconnecting members. 19.A method of manufacturing a mattress foundation kit, the methodcomprising: permanently laminating an at least one supporting materialonto each rail of a plurality of rails, wherein each rail of theplurality of rails is a longitudinal member constructed of a structuralfoam core; permanently laminating a plurality of interconnecting membersonto the plurality of rails, wherein each interconnecting member isconnected to at least one part of a corresponding rail of the pluralityof rails, wherein a first interconnecting member of a first rail of theplurality of rails is configured to detachably engage with a secondinterconnecting member of a second rail of the plurality of rails; andattaching a plurality of retainer clips along a side of at least tworails of the plurality of rails, wherein each retainer clip isconfigured to detachably engage with a slat of a plurality of slatsconfigured to support a mattress.
 20. The method of claim 19, whereinthe at least one supporting material comprises at least one of wood,plastic, metal, and composite material.
 21. The method of claim 19,wherein each of a top side and a bottom side of the structural foam coreis connected with the at least one supporting material.
 22. The methodof claim 19, wherein the plurality of interconnecting members comprisesa plurality of male interconnecting members and a plurality of femaleinterconnecting members, wherein a male interconnecting member isconfigured to detachably engage with a female interconnecting member.23. The method of claim 22, wherein each of a male interconnectingmember and a female interconnecting member are configured to be securedtogether by a securing member.
 24. The method of claim 23, wherein thesecuring member comprises a pin.